EP1971559B1 - Glaszusammensetzungen - Google Patents

Glaszusammensetzungen Download PDF

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Publication number
EP1971559B1
EP1971559B1 EP07733318A EP07733318A EP1971559B1 EP 1971559 B1 EP1971559 B1 EP 1971559B1 EP 07733318 A EP07733318 A EP 07733318A EP 07733318 A EP07733318 A EP 07733318A EP 1971559 B1 EP1971559 B1 EP 1971559B1
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EP
European Patent Office
Prior art keywords
glaze
boron
composition
frit
oxides
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EP07733318A
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English (en)
French (fr)
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EP1971559A1 (de
Inventor
Simon Gregson Cook
Miguel Joaquin Galindo Cercos
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US Borax Inc
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US Borax Inc
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Priority to PL07733318T priority Critical patent/PL1971559T3/pl
Publication of EP1971559A1 publication Critical patent/EP1971559A1/de
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
    • C03C17/34—Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions
    • C03C17/36—Surface treatment of glass, not in the form of fibres or filaments, by coating with at least two coatings having different compositions at least one coating being a metal
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/02—Pretreated ingredients
    • C03C1/026—Pelletisation or prereacting of powdered raw materials
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/02—Pretreated ingredients
    • C03C1/028—Ingredients allowing introduction of lead or other easily volatile or dusty compounds
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C03C8/02—Frit compositions, i.e. in a powdered or comminuted form
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C03C8/22—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions containing two or more distinct frits having different compositions

Definitions

  • This invention relates to frit-free, comminuted boron-containing compositions for use in glaze compositions, typically for application to ceramics, particularly ceramic tiles, their preparation and glaze compositions containing them.
  • Ceramic glaze technology has existed for thousands of years. Items that are glazed today include ceramic tableware, ceramic sanitaryware, heavy clay products such as roof tiles and bricks, ceramic wall and floor tiles. Generally, glazes comprise one or more glass frits as the major component with other raw materials such as clay, in an aqueous medium. The use of frit in glazes is dominated by wall and floor tiles, which probably account for more than 95% of all ceramic frits produced globally at the current time.
  • Glazes for tableware, heavy clay, and wall / floor tiles typically contain frit. Glazes for sanitaryware however, do not and are usually composed of raw materials only such as clay and other minerals and refined chemicals, all of which are insoluble in water.
  • Boron has long been recognised as an important component of glaze compositions. With conventional technology, it is only possible to incorporate boron in glazes by inclusion in a frit to render it insoluble. Boron as boric oxide has many beneficial functions in ceramic glazes when added as a frit. For example, it is a flux that does not increase thermal expansion and improves chemical durability. Boric oxide is also a valuable glaze constituent for eliminating the need for hazardous lead oxide in glazes.
  • boric oxide in glazes depends on the use of the glaze. In general, the higher the firing temperature for the glaze, the lower the boric oxide content required. In ceramic tiles, boric oxide remains an essential constituent in nearly all types of tile whether they are wall, floor, porous or vitrified. An exception is porcelain tiles as the high firing temperature negates the need for boron in the frit and boron-free frits are commercially available for this application.
  • Frits are usually prepared on a continuous basis by screw-feeding dry-mixed raw material batch in the appropriate composition ratio, to a furnace where the mixture is melted by being subjected to firing followed by fast cooling in water to obtain a glass. The glass is dried and ground into fine particles to form a glass frit.
  • the furnace comprises a refractory box supported on stilts, typically with a single gas burner at one end and the raw material feed at the other.
  • the exhaust is normally at the opposite end to the raw material feed.
  • the dimensions of the furnace are small compared to a glass furnace, typical areas are 10 to 12m 2 .
  • An alternative to a single burner is to have several small burners along the sides of the furnace.
  • the refractory lining is fused zirconia / alumina and must be replaced every few years.
  • the combustion system is normally fired by air/gas or oxy/gas.
  • air/gas the thermal efficiency is lower so the energy consumption is higher.
  • the energy cost is not necessarily higher due to the cost of the oxygen for oxy/gas firing.
  • the energy consumption depends on the type of furnace (the combustion system and the heat recovery system, if there is one) and the type of frit. Typical values are 290 Nm 3 gas per tonne of frit for air/gas and 190 Nm 3 gas per tonne of frit for oxy/gas firing. This is equivalent to 3.2 and 2.1 MWh per tonne of frit.
  • the furnace emits both dust and volatile species. Both are captured in a bag filter that operates at around 200°C.
  • the volatiles condense on cooling and can be captured with the dust.
  • the dust emissions are batch materials that are entrained in the combustion gases, and can have a range of composition.
  • the volatile species are mainly borates, which are volatile above 1200°C, especially in a wet atmosphere.
  • the material from the filter is recycled into the furnace. It is usual to have one filter per furnace. Some plants have one installation for the whole plant but this makes recycling of the dust much more difficult.
  • the alternatives to bag filters are electrostatic precipitators but these are not popular.
  • the raw material batch for a frit is dry-mixed and transferred to a silo before the furnace by pneumatic conveyor. From there it is screw-fed into the furnace. The mixture masses at one end of the furnace. The mass is kept constant by controlling the feed rate. Other parameters that are controlled are the temperature and pressure in the furnace. The fusion temperature is usually 1450-1500°C. As the mixture melts it forms a thin layer on the bottom of the furnace, 2-10cm thick, and flows down the furnace where it exits over a weir or through a hole in the furnace floor. Often there is a small burner at this point to keep the melt viscosity low.
  • the melt is quenched in a water bath to produce a glass.
  • the glass is extracted from the bath by a vibrating belt, dried, ground and transferred as a glass frit to suitable storage facilities.
  • Frits have many different compositions depending on the desired end use, though most ceramic frit producers have a very similar range of products. Tiles are classified into five categories depending on the materials used to make the body of the tile, and whether the tile is a wall or floor tile. Within each of the five categories, there are different types of frit available to give glossy transparent, glossy white and matt surfaces, for example. Thus, the typical frit manufacturer has an extensive range of products, maybe around 50. Of these, probably ten frits account for 80% of its output, which is destined for glazing wall tiles, and comprise frits having similar compositions. The remainder accounts for the other 20% of volume for all other applications. These require many modifications to formulations.
  • Production costs are relatively high and need to be reduced to compete with low cost countries, such as by reducing energy consumption.
  • Glazes for ceramic tiles have several functions. They impart an aesthetically-pleasing aspect, give the porous ceramic body a non-porous coating, give adequate chemical durability, give mechanical durability such as hardness and abrasion resistance, and give slip resistance.
  • Glaze is applied by any of a variety of automated methods that may be by spray, spinning disc, rubber roller or waterfall (bell).
  • the most common method is the waterfall or bell method, where tiles move under a curtain of glaze created by flowing the glaze down the outer surface of a metal bell.
  • the most modem tile technology is single fast firing, in which the ceramic tile body and glaze are fired simultaneously. Typical cycles are well under one hour in length, from cold to cold, with only a few minutes at maximum temperature. Slightly older technology is double fast firing, in which the tile body is fired once before the glaze is applied, and the body/glaze combination is then fired a second time. This technology is less energy and labour-efficient than single firing and hence has been in decline since the development of single firing.
  • Frits are used in glazes to render the desired soluble elements sodium, potassium and boron insoluble in water. They need to be insoluble since soluble elements will migrate during drying processes that give rise to glaze defects as well as the possibility of effluent problems as they would be present in wastewaters.
  • the frit also ensures that the melting process commences at an early stage, that is before the glaze firing process itself. This ensures that high gloss in the glaze firing process is easily obtained.
  • frits have been sought. These must exhibit essentially the same properties as a frit to make them useful in glaze compositions.
  • the material must be low in solubility, in particular boron solubility. If not, it will not be as desirable as a frit as defects in the glaze would likely result as well as soluble boron being unwanted for effluent reasons. It must also give a good glaze result on firing and must not be too refractory to melt during the glaze firing process.
  • Glazes that do not contain frits are known.
  • a Kartal in cfi/Ber. DKG 79 (2002) No. 3 describes methods for replacing frits for floor tile glazes with a calcined natural boron compound like colemanite.
  • the calcined colemanite is also recommended as a partial replacement of frit for wall tile glazes, particularly for single fired wall tiles.
  • the composition obtained according to this reference has an aqueous solubility of boron that is significantly higher than a frit and thus limits the use of such compositions.
  • JP 57027942 describes a glaze comprising commercial waste glass with the addition of ulexite so as to give a slurry.
  • Ulexite is a mineral comprising 5-10 wt% sodium oxide, 10-20 wt% calcium oxide and 40-50 wt% boric oxide.
  • SU 872476 refers to compositions of glazes used for the production of glazed ceramic tiles.
  • EP 0202551 refers to a silicate raw material for ceramics containing alkali oxides, zinc oxide and silicon dioxide.
  • WO 01/04065 provides a method of contemporaneously, forming a particulate glass batch composition and reducing volatile components in an exhaust stream.
  • a frit-free, comminuted boron-containing composition for use in glaze production which composition is obtainable by a process which comprises heating to a temperature sufficiently high that calcination occurs but insufficient for formation of a homogeneous melt, suitably to a temperature of 750 to 1300°C, a mixture comprising components capable, under the conditions of heating, of forming the oxides B 2 O 3 , SiO 2 , Al 2 O 3 , Na 2 O and optionally CaO in proportions such that the relative percentages by weight of the said oxides, based on the total weight of the said oxides, are as follows:
  • the boron-containing compositions according to the invention can be used in frit-free glaze compositions to provide boron-containing glazes with low boron solubility for general use in glazing compositions.
  • the boron-containing compositions according to the invention can be used in frit-free glaze compositions having excellent gloss and durability meeting the requirements of traditional glaze compositions.
  • the boron-containing compositions according to the invention can be used in the glazing of ceramic articles with frit-free glaze compositions that meet the criteria of conventional frit-containing glaze compositions.
  • the boron-containing compositions according to the invention can be used in total or partial replacement of frits in glaze compositions.
  • the boron-containing compositions according to the invention can be used in frit-free glaze compositions which provide glazes having a boron solubility as low as that of boron-containing frits and much lower than previously described frit-free compositions.
  • a glaze composition suitably a frit-free or boron-free frit containing glaze composition, containing a boron-containing composition according to the invention.
  • a boron-containing composition according to the invention in a glaze composition, suitably a frit-free or boron-free frit-containing glaze composition.
  • a process for preparing a boron-containing composition for use in a glaze composition which process comprises
  • a composition in particulate form comprising a mixture of components capable, under the conditions of heating, of yielding the oxides B 2 O 3 , SiO 2 , Al 2 O 3 , Na 2 O, and optionally CaO in proportions such that the relative percentages by weight of the said oxides, based on the total weight of the said oxides, are as follows:
  • a method of glazing a ceramic article which method comprises applying to a surface of the ceramic article a glaze composition according to the invention, and firing the ceramic article.
  • the raw materials do not form an homogeneous melt on heating. This in particular contrasts with the production of frits which involve melting to form homogeneous glasses. Accordingly the boron-containing compositions according to the present invention can be manufactured at lower temperatures, and thus at less cost, than frits.
  • the calcination temperature may be typically 500°C lower than a typical frit fusion temperature, and the calcination time is around 70% shorter than that for frit manufacture. This gives a very significant reduction in the energy required to produce a ceramic glaze without affecting the energy required to fire the glaze, i.e. the glazing process is essentially the same for both conventional frit-containing glazes and those according to the invention.
  • the cost of glazes containing the compositions according to the invention is typically lower than for conventional flitted glazes. This is because the amount of the calcined composition in the glaze is generally lower than the amount of frit required in conventional glazes. The overall cost of the calcined composition may also be lower than the cost of a frit, depending on the composition of the frit.
  • Raw materials used according to the present invention form B 2 O 3 , SiO 2 , Al 2 O 3 ; Na 2 O and optionally CaO under the calcinations conditions.
  • a mixture of sodium borate which acts as a source of B 2 O 3 and Na 2 O
  • kaolin which acts as a source of Al 2 O 3 and SiO 2
  • quartz which acts a source of SiO 2
  • optionally wollastonite which acts as a source of CaO.
  • Each of the ingredients of the composition serves particular functions.
  • Boron gives a strong fluxing action in the calcination process and in the glaze firing process.
  • the boron compound must be used in powder form in order to obtain good mixing before calcination.
  • sodium borates sodium tetraborate pentahydrate (borax pentahydrate), commercially available under the brand name Neobor ® , is preferred.
  • Borax decahydrate can also be used but is not as cost-effective as borax pentahydrate.
  • Non-sodium borates such as boric acid, boric oxide and colemanite are free from sodium oxide and hence not as suitable for this application as sodium borates unless they are augmented with sodium from an alternative source that on heating will be equivalent to the desired oxide definition.
  • a suitable such material is soda ash.
  • the mineral ulexite is a sodium-calcium borate and is suitable for use, but again it is less cost effective than borax pentahydrate.
  • Silica (SiO 2 ) gives some glassy phase during calcination by reaction with the borate and any wollastonite. If silica is not employed then the resulting composition would have a desired low water solubility, although it would be too refractory for use as a glaze constituent.
  • the particle size of the preferred quartz is important. If it is too large it does not react sufficiently during calcination, which gives rise to undissolved quartz particles in the calcined compositions. These in turn give rise to low glaze gloss since they do not dissolve in the glaze during firing.
  • the preferred particle size for quartz as used in this invention is ⁇ 400 mesh (D 50 11 ⁇ m) e.g. Millisil C400 from Sifraco, Paris.
  • quartz are other finely ground materials rich in silica but they should suitably also be low in iron, titanium and other colouring oxides to minimise colouring of the final glaze.
  • These may be, for example, feldspar, feldspathic sand or waste materials such as ground float or container glass cullet (transparent, not coloured).
  • Kaolin is the preferred material to provide alumina (Al 2 O 3 ) to impart low water solubility to the boron-containing compositions of the invention. It also supplies part of the SiO 2 component. Without it the water solubility of the compositions would be usually significantly higher than a ceramic frit thus rendering them unsuitable for glaze applications.
  • the quality of the kaolin (proportion of colouring oxides present as impurities) is important and must be high, in order to minimise yellowing of the glaze.
  • Kaolin is used as a powder.
  • the principal function of kaolin is to provide Al 2 O 3 but there are suitable alternatives being other powdered materials rich in Al 2 O 3 and low in iron, titanium and other colouring oxides to minimise undesired colouring in the finished glaze.
  • feldspar kyanite / andalusite / sillimanite (all Al 2 O 3 .SiO 2 ), mullite (2Al 2 O 3 .2SiO 2 ), calcined alumina (Al 2 O 3 ), and alumina trihydrate (Al(OH) 3 ).
  • kaolin gives good results and is the most economical way to add alumina.
  • all kaolins no matter how "clean" and high in quality, contain some colouring oxides as impurities such as Fe 2 O 3 and TiO 2 .
  • the oxides can impart a slight yellow colour to some glazes formulated with the calcined material, reducing the glaze quality.
  • additional quartz will be required. This has an impact on the raw materials cost, which increases.
  • Wollastonite provides a preferred source of calcium oxide (CaO) to react with borate and quartz in a glassy phase.
  • CaO calcium oxide
  • the presence of CaO has a marked effect on the calcination temperature, reducing it by around 100°C. It also reduces the refractoriness of the calcined borate when it is used in a glaze, resulting in a higher gloss.
  • Other forms of CaO for example burnt lime (CaO), calcium hydroxide (Ca(OH) 2 ) and limestone (CaCO 3 ) may be used but are less suitable as they give rise to gas emissions during the calcination process.
  • Wollastonite is typically used as a powder having a particle size of less than 75 ⁇ m.
  • the heating of the raw materials is to a temperature sufficiently high to achieve calcination, whereby water and carbon dioxide are driven off.
  • the temperature however is not so high as to result in the mixture becoming molten.
  • the mixed raw materials, in finely divided form are typically heated to a temperature of 750 to 1300°C, preferably 1050 to 1250°C, for typically 90 minutes. In the event that temperatures towards the higher end of the range may be used, shorter heating times may be employed. Under the heating conditions there may be some interaction between the oxides formed and the product may be generally partly crystalline and partly glassy. The nature of this interaction is however not fully understood.
  • the boron-containing compositions according to the invention are prepared by heating to a temperature sufficiently high that calcination occurs but insufficient for formation of a homogenous melt, suitably to a temperature of 750 to 1300°C. This gives a material which has a boron solubility as low as that of a boron-containing frit, which is surprising since full melting of the composition is not used, and it is generally accepted that to render boron insoluble it is necessary to fully melt a boron-containing frit or glass composition.
  • the preparation method for the composition according to the invention makes deliberate use of a low temperature eutectic in the Na 2 O.B 2 O 3 .SiO 2 .system (see G. W. Morey, J. Soc. Glass. Tech., 35, 270 (1051 ), the content of which is incorporated herein by reference).
  • the eutectic occurs at a temperature of 577°C, and when heating mixtures containing Na 2 O, B 2 O 3 and SiO 2 reaction will start at this temperature, forming some glassy material. On further heating the glassy material will start to dissolve some Al 2 O 3 from the other raw materials which will increase its durability, in other words decrease its solubility in water.
  • This is the mechanism through which the boron-containing compositions according to the invention are produced with a low solubility of boron. It is nevertheless surprising that the boron solubility is as low as has been measured.
  • the boron-containing glaze components of the invention may be made by first dry mixing the finely divided raw materials. Water is added slowly until the materials form a crumb. The crumb is dried at 100°C until all water has been removed.
  • calcination may be carried out by placing the dried crumb in a suitable receptacle, such as a fireclay crucible, and firing it in a furnace, typically an electric muffle furnace. A typical heating cycle is 10°C per minute up to the selected temperature, of generally 1050 to 1250°C. It is held at this temperature for approximately 90 minutes and then allowed to cool naturally on switching off the furnace to complete the calcination step.
  • the material After the heat treatment the material is removed from the receptacle and crushed carefully. In view of the hardness of the material, it is protected from any metal parts to avoid contamination that may lead to glaze defects.
  • the appearance of the material obtained is distinct from a ceramic frit.
  • a ceramic frit is nearly always transparent, often with a slight blue or green tinge due to the presence of some colouring impurities.
  • the material according to the invention is opaque, typically a creamy-white colour, sometimes with a pink tinge (depending on the composition).
  • the raw materials are granulated with water but then calcined by suitable means such as a continuous rotary calciner. This method ensures that the particles do not adhere to each other during calcination, thus removing the need for a crushing step before comminution.
  • Preferred boron-containing glaze components according to the invention comprise the following by weight: Preferred Particularly preferred (i) SiO 2 50 - 65% 60.5% (ii) Al 2 O 3 17 - 24% 19% (iii) B 2 O 3 10 - 13% 10.5% (iv) CaO 4 - 7% 5% (v) Na 2 O 5 - 7% 5%
  • the balance is generally made up of impurities comprising less than 1% of any of Fe 2 O 3 , MgO, K 2 O and TiO 2 , and less than 0.1% of ZrO 2 , BaO, PbO, P 2 O 5 and SrO of the total composition.
  • the boron-containing compositions according to the present invention may be used in frit-free glaze compositions.
  • the glaze compositions according to the present invention may contain frits, particularly boron-free frits, in addition to the boron-containing glaze compositions according to the present invention.
  • Glazes according to the present invention normally comprise the glaze component according to the present invention, an optional frit component, clay and all other minor amounts of additives, dispersed in water forming a slurry.
  • a glaze composition according to the invention in the form of a slurry, having a solids content of between 65 and 70%, is coated on a pressed and dried green body, and the coated ceramic body is fired at a temperature of between 1100 and 1200°C.
  • Ceramic bodies which may be glazed according to the present invention include wall tiles and floor tiles and these may be, according to the composition of the glazed used, be provided with a glossy, matt or satin appearance.
  • the glaze compositions of the invention can also be applied to engobes.
  • An engobe is an opaque coating that is often applied to the tile body before glazing. Its function is to mask the tile body, for example, when it is produced using red clay. Engobes conventionally contain frits and raw materials but the frit content is typically much lower than in a glaze.
  • Finely divided sodium tetrahydrate pentahydrate (Neobor ex Borax Europe Limited 80g), quartz (100g), kaolin (180g) and wollastonite (40g) were dry mixed in a small mixer stirred at low speed. Water was added slowly through a syringe until the mixture formed a crumb. The crumb was heated at 100°C until it was completely dry. The dried product was transferred to a fireclay crucible and placed in an electric muffle furnace. The furnace was heated at a rate of 10°C per minute up to a maximum of 1050°C where the temperature was held for 90 minutes. The furnace was then switched off and the crucible was allowed to cool to ambient temperature in the furnace.
  • the product was removed, wrapped in a plastic film and broken up with a hammer.
  • the resulting composition was opaque with a creamy-white colour and in particulate form.
  • Example B 2 O 3 (%) SiO 2 (%) Al 2 O 3 (%) Na 2 O (%) CaO (%) 1 10.5 60.5 19 5 5 2 13 51 20 6.6 7 3 17 41 31 8 - 4 13 54 24 6.6 -
  • Example 1 to 4 The compositions obtained in Example 1 to 4 were formulated into glaze compositions which were applied to ceramic wall tiles and fired.
  • the ingredients were milled in a laboratory fast jar mill, using alumina grinding balls.
  • the wet method was used (with water) using a slurry solids content of 70%.
  • the glaze contained a carboxymethylcellulose binder and a sodium tripolyphosphate deflocculant, both of which were added to the water before milling at 0.3% relative to the glaze solids.
  • the glaze was milled until there was less than 1% residue on a standard 40 ⁇ m sieve.
  • the glaze composition was applied to ceramic wall tiles using a modified paint film applicator.
  • the applicator had a 0.6mm wide slot through which the glaze flowed.
  • the applicator speed and slot width were selected to ensure a glaze deposit dry weight in g/m 2 similar to those in industrial applications. Typically 600 to 800 g/m 2 was obtained.
  • Glaze firing was carried out in an electric laboratory furnace, using a heating and cooling rate of 25°C per minute, with 6 minutes at maximum temperature.
  • Sealing temperature was measured by firing the glaze as normal, but by varying the maximum temperature in 10°C intervals. The fired glazes were examined using a dye penetration test to determine whether they were sealed. In this way the sealing temperature can be specified as a 10°C range.
  • Sintering, softening, sphere, half-sphere and fusion point were all measured using a heating microscope.
  • the sample was prepared from milled and dried glaze, by pressing in a small manual die. A drop of water was used to bind the sample, which was in the form of a cylinder 3mm in height and 2mm in diameter.
  • the sample was introduced into the microscope, heated at a constant rate (typically 25°C per minute), and images were recorded in silhouette by a computer. At the end of the heating cycle the images were automatically processed using image analysis, to determine the five parameters.
  • the surface of the glaze tile was wiped with acid or alkali solution and marked (with permanent marker or pencil). It was then observed whether removal of the marking left any visible effect.
  • GHB - indicates there are no visible effects when a permanent marker has been used
  • GHA - indicated there are no visible effects when a pencil has been used.
  • Glaze compositions were prepared from the specified ingredients and applied to wall tiles having an engobe and fired at 1100°C to provide a matt finish. Heating microscope and chemical reactivity/durability tests as well as gloss and colour measurements were carried out.
  • Ingredient Conventional glaze (comparative) (g) Glaze according to invention (g) Kaolin 8 8 Product of Example 1 28.6 Soda feldspar 30 30 Wollastonite 41.4 Conventional boron frit 70 Total 108 108
  • Glaze compositions were prepared from the specified ingredients, applied to red body floor tiles (with and without engobe), and fired at 1140°C. The resulting glazes had a glossy finish.
  • Ingredient Conventional glaze (comparative) (g) Glaze according to the invention (g) Kaolin 7 8 Product of Example 1 30 Quartz 19 Zinc oxide 5 Zircosil 5* 10 8 Nepheline syenite 9 Soda feldspar 17 57 Conventional boron frit 38 Total 100 108 * Zircosil 5 is a zircon opacifier ex-Johnson Matthey.
  • Glaze compositions were prepared from the specified ingredients, applied to red body floor tiles (without engobe), and fired at 1140°C. The resulting glazes had a satin finish.
  • Ingredient Conventional glaze (comparative) (g) Glaze according to the invention (g) Kaolin 8 8 Product of Example 1 30 Wollastonite 14 Zinc oxide 10 Alumina 8 Nepheline syenite 9 Soda feldspar 12 38 Conventional boron frit 70 Total 99 108 Glaze colour and gloss L 74.0 67.9 a 0.61 0.87 b 2.09 3.58 Gloss (%) 14 10
  • Glaze compositions were prepared from the specified ingredients, applied to red body floor tiles (with and without engobe), and fired at 1140°C. The resulting glazes had a matt finish.
  • Ingredient Conventional glaze (comparative) (g) Glaze according to the invention (g) Kaolin 5 8 Product of Example 1 30 Quartz 4 Zinc oxide 2 Alumina 12 Zircosil 5 7 7 3 Nepheline syenite 12 Soda feldspar 14 67 Wollastonite 19 Conventional boron frit 24 Total 99 108
  • Glaze compositions were prepared from the specified ingredients, applied to porcelain tiles (with and without engobe), and fired at 1180°C. The resulting glazes had a glossy finish.
  • Ingredient Conventional glaze (comparative)
  • Glaze according to the invention (g) Kaolin 6 8 Product of Example 1 30 Quartz 16 Zinc oxide 0.5 Alumina 4 Zircosil 5 9 3 Soda feldspar 67 Conventional boron frit 64 Total 99.5 108
  • Glaze compositions were prepared from the specified ingredients, applied to porcelain tiles (with and without engobe), and fired at 1180°C. The resulting glazes had a satin finish.
  • Ingredients Conventional glaze (comparative) (g) Glaze according to the invention (g) Kaolin 6 8 Product of Example 1 30 Zinc oxide 6 Alumina 3 6 Zircosil 5 3 Soda feldspar 9 45 Wollastonite 10 Conventional boron frit 72 Total 100 108
  • Glaze compositions were prepared from the specified ingredients, applied to porcelain tiles (without engobe), and fired at 1180°C. The resulting glazes had a matt finish.
  • Ingredient Conventional glaze (comparative) (g) Glaze according to the invention (g) Kaolin 5 8 Product of Example 1 30 Quartz 4 Zinc oxide 2 Alumina 12 3 Zircosil 5 7 7 Nepheline syenite 12 Soda feldspar 14 50 Wollastonite 19 10 Conventional boron frit 24 Total 99 108
  • the results of the glaze characterisation tests were as follows: Glaze colour and gloss L 85.9 88.0 a 0.08 0.07 b 5.92 5.02 Gloss (%) 7 14
  • Example 2 can be used to easily produce glazes with a range of gloss levels.
  • This example compares a conventional boron-containing frit containing glaze composition with a boron free frit containing glaze composition according to the invention.
  • the boron-free frit used was made by conventional means from the following raw materials (% by weight): BaCO 3 5.8 CaCO 3 25.4 KNO 3 6.0 Quartz 53.8 ZnO 8.9
  • the resulting boron-free frit had an oxide composition (% by weight) as follows: BaO 5.3 CaO 16.8 K 2 O 3.4 SiO 2 63.4 ZnO 10.6.
  • Glaze compositions having the compositions below were applied to wall tiles (without engobe), and fired at 1100-1120°C. High gloss transparent glazes were obtained.
  • Ingredient Conventional glaze (comparative)
  • Glaze according to the invention (g) Kaolin 8 8 Product of Example 3 18.5 Boron-free frit 73.5 Conventional boron frit 92 Total 100 100
  • Example 3 has also been used without frit to produce a matt glaze for porcelain tiles fired at 1180°C. Though in view of its relatively high melting temperature, it is generally suitable for use in fritted glazes or for matt glazes to be fired at higher temperatures i.e. 1180°C or above.
  • the example also comprises a conventional boron-containing frit containing glaze composition with a boron-free frit containing glaze composition according to the invention based here on the product of Example 4.
  • the boron-free frit used was made by conventional means from the following raw materials (% by weight): BaCO 3 6.2 CaCO 3 26.6 KNO 3 6.5 Quartz 51.3 ZnO 9.4.
  • the resulting boron-free frit had an oxide composition (% by weight) as follows: BaO 5.7 CaO 17.8 K 2 O 3.7 SiO 2 61.0 ZnO 11.3.
  • Glaze compositions having the composition below are applied to wall tiles (without engobe) and fired at 1100 - 1120°C. High gloss transparent glazes were obtained.
  • Ingredient Conventional glaze (comparative)
  • Glaze according to the invention (g) Kaolin 8 8 Product of Example 4 23.2 Boron-free frit 68.8 Conventional boron frit 92 Total 100 100
  • Glaze gloss Gloss at 1100°C (%) 98 91 Glaze sealing temperature Sealing temperature (°C) 940-950°C 900-910°C Heating microscope properties Start of contraction (°C) 820 770 End of contraction (°C) 970 970 Softening point (°C) 1030 Irregular shape Sphere point (°C) 1100 1150 Half sphere point (°C) 1240 1180 Fusion point (°C) 1270 1200
  • Example 4 was inferior to that of Example 3 in terms of glaze appearance.
  • the glaze composition did, however, exhibit similar properties to tiles coated with a conventional glaze.

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Claims (12)

  1. Frittenfreie, zerkleinerte Bor-enthaltende Zusammensetzung zur Verwendung in der Glasherstellung, wobei die Zusammensetzung erhältlich ist durch ein Verfahren, das umfasst
    (a) Erhitzen bis zu einer Temperatur, die ausreichend hoch ist das ein Kalzinieren stattfindet aber nicht ausreicht für die Bildung einer homogenen Schmelze, einer Mischung, die Bestandteile umfasst, die in der Lage sind unter Heizbedingungen die Oxide B2O3, SiO2, Al2O3, Na2O und optional CaO anteilsmäßig derart zu bilden, dass die relativen Gewichtsprozente der genannten Oxide, basierend auf dem gesamten Gewicht der genannten Oxide, wie folgt sind:
    10 bis 18 % B2O3
    40 bis 65 % SiO2
    17 bis 32% Al2O3
    4 bis 9% Na2O,
    0 bis 10% CaO, und
    (b) dann Zerkleinern der resultierenden Zusammensetzung.
  2. Zusammensetzung nach Anspruch 1, in der die genannten Anteile der genannten Oxide wie folgt sind:
    10 bis 13 % B2O3
    50 bis 65 % SiO2
    17 bis 24% Al2O3
    5 bis 7% Na2O, und
    4 bis 7% CaO.
  3. Zusammensetzung nach Anspruch 1 oder 2, in der als Ausgangsmaterialien nach Gewicht, basieren auf dem gesamten Gewicht dieser Bestandteile, genutzt werden:
    Natriumborat 10-30%
    Quartz 20-30%
    Kaolin 30-50%
    Wollastonit 7,5-15%.
  4. Zusammensetzung nach irgendeinem der vorangegangenen Ansprüche, in der die genannte Mischung auf 1050 bis 1250°C erhitzt wird.
  5. Verfahren zur Herstellung einer Bor-enthaltenden Zusammensetzung zur Verwendung bei einer Glasherstellung, wobei das Verfahren umfasst
    (a) Erhitzen bis zu einer Temperatur, die ausreichend hoch ist das ein Kalzinieren stattfindet aber nicht ausreicht für die Bildung einer homogenen Schmelze, einer Mischung, die Bestandteile umfasst, die in der Lage sind unter Heizbedingungen die Oxide B2O3, SiO2, Al2O3, Na2O und optional CaO anteilsmäßig derart zu ergeben, dass die relativen Gewichtsprozente der genannten Oxide, basierend auf dem gesamten Gewicht der genannten Oxide, wie folgt sind:
    10 bis 18 % B2O3
    40 bis 65 % SiO2
    17 bis 32% Al2O3
    4 bis 9% Na2O,
    0 bis 10% CaO, und dann
    (b) Zerkleinern der resultierenden Zusammensetzung.
  6. Verfahren nach Anspruch 5, in dem die genannten Anteile der genannten Oxide wie folgt sind:
    10 bis 13 % B2O3
    50 bis 65 % SiO2
    17 bis 24% Al2O3
    5 bis 7% Na2O, und
    4 bis 7% CaO.
  7. Verfahren nach Anspruch 5 oder 6, in dem als Ausgangsmaterialien nach Gewicht, basieren auf dem gesamten Gewicht dieser Bestandteile, genutzt werden:
    Natriumborat 10-30%
    Quartz 20-30%
    Kaolin 30-50%
    Wollastonit 7,5-15%.
  8. Verfahren nach irgendeinem der Ansprüche 5 bis 7, in dem die genannte Mischung auf 1050 bis 1250°C erhitzt wird.
  9. Glaszusammensetzung, die eine Bor-enthaltende Zusammensetzung wie beansprucht in irgendeinem der Ansprüche 1 bis 4 umfasst.
  10. Glaszusammensetzung nach Anspruch 9, die außerdem Bor-freie Fritte enthält.
  11. Verwendung einer Bor-enthaltenden Zusammensetzung wie beansprucht in irgendeinem der Ansprüche 1 bis 4 in einer Glaszusammensetzung.
  12. Verfahren zum Glasieren eines Keramikartikels, wobei das Verfahren umfasst Auftragen einer Glaszusammensetzung wie beansprucht in Anspruch 9 oder 10 auf die Oberfläche des Keramikartikels und Brennen des Keramikartikels.
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Publication number Priority date Publication date Assignee Title
RU2463265C1 (ru) * 2011-05-27 2012-10-10 Юлия Алексеевна Щепочкина Масса для получения эмалевого покрытия
RU2481275C1 (ru) * 2011-12-29 2013-05-10 Юлия Алексеевна Щепочкина Шихта для изготовления глазури
RU2498966C1 (ru) * 2012-07-17 2013-11-20 Юлия Алексеевна Щепочкина Кирпичная глазурь
RU2506249C1 (ru) * 2012-10-05 2014-02-10 Юлия Алексеевна Щепочкина Глазурь
RU2507166C1 (ru) * 2012-10-05 2014-02-20 Юлия Алексеевна Щепочкина Глазурь
RU2541703C1 (ru) * 2014-02-25 2015-02-20 Юлия Алексеевна Щепочкина Цветная глазурь
EP4230600A1 (de) * 2022-02-16 2023-08-23 Guangdong Deer New Materials Co., Ltd. Extrem verschleissbeständige weichlicht-diamantglasur, keramikfliese und herstellungsverfahren dafür

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KR101036093B1 (ko) 2011-05-19
RU2421409C2 (ru) 2011-06-20
TNSN08342A1 (en) 2009-12-29
ES2310503T3 (es) 2011-02-21
WO2007148101A1 (en) 2007-12-27
ATE479635T1 (de) 2010-09-15
GB0612316D0 (en) 2006-08-02
UA93227C2 (ru) 2011-01-25
CN101365656A (zh) 2009-02-11
MA30306B1 (fr) 2009-04-01
TW200925129A (en) 2009-06-16
PT1971559E (pt) 2010-10-25
US20080311302A1 (en) 2008-12-18
JP2009525251A (ja) 2009-07-09
MY148944A (en) 2013-06-14
EP1971559A1 (de) 2008-09-24
JP5139327B2 (ja) 2013-02-06
US7892997B2 (en) 2011-02-22
EG25710A (en) 2012-05-30
PL1971559T3 (pl) 2011-02-28
DE602007008823D1 (de) 2010-10-14
RU2008131290A (ru) 2010-02-10
CN101365656B (zh) 2012-04-25
BRPI0706627A2 (pt) 2011-04-05
TWI359798B (en) 2012-03-11
ES2310503T1 (es) 2009-01-16
KR20080085013A (ko) 2008-09-22

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